Download Stanton RM-80 DJ Equipment User Manual

2004 IMPREZA SERVICE MANUAL
QUICK REFERENCE INDEX
ENGINE SECTION 2
This service manual has been prepared
to provide SUBARU service personnel
with the necessary information and data
for the correct maintenance and repair
of SUBARU vehicles.
This manual includes the procedures
for maintenance, disassembling, reassembling, inspection and adjustment of
components and diagnostics for guidance of experienced mechanics.
Please peruse and utilize this manual
fully to ensure complete repair work for
satisfying our customers by keeping
their vehicle in optimum condition.
When replacement of parts during
repair work is needed, be sure to use
SUBARU genuine parts.
FUEL INJECTION (FUEL SYSTEMS)
FU(H4DOTC)
EMISSION CONTROL
(AUX. EMISSION CONTROL DEVICES)
EC(H4DOTC)
INTAKE (INDUCTION)
IN(H4DOTC)
MECHANICAL
ME(H4DOTC)
EXHAUST
EX(H4DOTC)
COOLING
CO(H4DOTC)
LUBRICATION
LU(H4DOTC)
SPEED CONTROL SYSTEMS
SP(H4DOTC)
IGNITION
IG(H4DOTC)
STARTING/CHARGING SYSTEMS
SC(H4DOTC)
ENGINE (DIAGNOSTICS)
EN(H4DOTC)(diag)
All information, illustration and specifications contained in this manual are
based on the latest product information
available at the time of publication
approval.
FUJI HEAVY INDUSTRIES LTD.
G1870GE3
MECHANICAL
ME(H4DOTC)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Page
General Description ....................................................................................2
Compression .............................................................................................34
Idle Speed .................................................................................................35
Ignition Timing...........................................................................................36
Intake Manifold Vacuum............................................................................37
Engine Oil Pressure ..................................................................................38
Fuel Pressure............................................................................................39
Valve Clearance........................................................................................40
Engine Assembly ......................................................................................44
Engine Mounting .......................................................................................52
Preparation for Overhaul...........................................................................53
V-belt.........................................................................................................54
Crankshaft Pulley ......................................................................................56
Timing Belt Cover......................................................................................57
Timing Belt Assembly................................................................................58
Camshaft Sprocket....................................................................................66
Crankshaft Sprocket..................................................................................68
Camshaft...................................................................................................69
Cylinder Head Assembly...........................................................................78
Cylinder Block ...........................................................................................85
Intake and Exhaust Valve .......................................................................105
Piston ......................................................................................................106
Connecting Rod ......................................................................................107
Crankshaft...............................................................................................108
Engine Trouble in General ......................................................................109
Engine Noise...........................................................................................114
General Description
MECHANICAL
1. General Description
A: SPECIFICATIONS
1. DOHC TURBO MODEL (EXCEPT FOR STi AND AUSTRALIA MODEL)
Type
Valve arrangement
Bore × Stroke
mm (in)
Piston displacement
3
Intake valve timing
Exhaust valve timing
Valve clearance
8.0
kPa (kgf/cm2, psi)
Opening
Closing
Opening
Closing
Intake
Exhaust
Belt
tension
adjuster
I.D.: Inner Diameter
700±100 (No load)
800±150 (A/C switch ON)
1→3→2→4
12°±10°/700
BTDC/rpm
O.D.: Outer Diameter
OS: Oversize
Protrusion of adjuster rod
Clearance between spacer and bush
STD
Limit
STD
Limit
Bend limit
Thrust clearance
Intake
Cam lobe height
Camshaft
Exhaust
Journal O.D.
Oil clearance
US: Undersize
5.2 — 6.2 mm (0.205 — 0.244 in)
Side clearance of spacer
Cylinder
head
Pressure ring: 2, Oil ring: 1
BTDC 10°
ABDC 50°
BBDC 53°
ATDC 7°
0.20±0.02 (0.0079±0.0008)
0.35±0.02 (0.0138±0.0008)
rpm
Spacer O.D.
Tensioner bush I.D.
Belt
tensioner
981 — 1,177 (10 — 12, 142 — 171)
mm (in)
mm (in)
Idling speed
[At neutral position on MT or “P” or
“N” range on AT]
Firing order
Ignition timing
NOTE:
STD: Standard
1,994 (121.67)
cm (cu in)
Compression ratio
Compression pressure (at 200 — 300
rpm)
Number of piston rings
Engine
Horizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Belt driven, double overhead camshaft, 4-valve/cylinder
92 × 75 (3.62 × 2.95)
STD
STD
Limit
STD
Limit
STD
Limit
Front
Center
rear
STD
Limit
17.955 — 17.975 mm (0.7069 — 0.7077 in)
18.0 — 18.08 mm (0.7087 — 0.7118 in)
0.025 — 0.125 mm (0.0010 — 0.0049 in)
0.175 mm (0.0069 in)
0.2 — 0.55 mm (0.0079 — 0.0217 in)
0.81 mm (0.0319 in)
0.020 mm (0.0079 in)
0.040 — 0.080 mm (0.0016 — 0.0031 in)
0.10 mm (0.0039 in)
46.25 — 46.35 mm (1.821 — 1.825 in)
46.15 mm (1.817 in)
46.15 — 46.25 mm (1.817 — 1.821 in)
46.05 mm (1.813 in)
37.946 — 37.963 mm (1.4939 — 1.4946 in)
29.946 — 29.963 mm (1.1790 — 1.1796 in)
Surface warpage limit
Surface grinding limit
Standard height
ME(H4DOTC)-2
0.037 — 0.072 mm (0.0015 — 0.0028 in)
0.10 mm (0.0039 in)
0.05 mm (0.0020 in)
0.3 mm (0.012 in)
127.5 mm (5.02 in)
General Description
MECHANICAL
Refacing angle
Valve seat
Intake
Contacting width
Exhaust
Valve guide
Inner diameter
Protrusion above head
Intake
Head edge thickness
Exhaust
Valve
STD
Limit
STD
Limit
Stem diameter
Stem oil clearance
STD
Limit
Overall length
STD
Limit
STD
Limit
Intake
Exhaust
Intake
Exhaust
—
Intake
Exhaust
Free length
Squareness
Valve
spring
Set
Tension/spring height
Lift
Cylinder
block
Piston
Piston pin
Surface warpage limit (mating with cylinder head)
Surface grinding limit
A
Cylinder bore
STD
B
STD
Taper
Limit
STD
Out-of-roundness
Limit
STD
Piston clearance
Limit
Enlarging (boring) limit
A
STD
B
0.25
mm
(0.0098
in)
Outer diameter
OS
0.50 mm (0.0197 in)
OS
STD
Standard clearance between piston
pin and hole in piston
Limit
Degree of fit
90°
1.0 mm (0.039 in)
1.7 mm (0.067 in)
1.5 mm (0.059 in)
2.2 mm (0.087 in)
6.000 — 6.012 mm (0.2362 — 0.2367 in)
15.8 — 16.2 mm (0.622 — 0.638 in)
1.2 mm (0.047 in)
0.8 mm (0.031 in)
1.5 mm (0.059 in)
0.8 mm (0.031 in)
5.955 — 5.970 mm (0.2344 — 0.2350 in)
5.945 — 5.960 mm (0.2341 — 0.2346 in)
0.030 — 0.057 mm (0.0012 — 0.0022 in)
0.040 — 0.067 mm (0.0016 — 0.0026 in)
0.15 mm (0.0059 in)
104.4 mm (4.110 in)
104.7 mm (4.122 in)
47.32 mm (1.8630 in)
2.5°, 2.1 mm (0.083 in)
205 — 235 N (20.9 — 24.0 kgf, 46.1 — 52.8 lb)/
36.0 mm (1.417 in)
426 — 490 N (43.4 — 50.0 kgf, 95.8 — 110 lb)/
26.5 mm (1.043 in)
0.05 mm (0.0020 in)
0.1 mm (0.004 in)
92.005 — 92.015 mm (3.6222 — 3.6226 in)
91.995 — 92.005 mm (3.6218 — 3.6222 in)
0.015 mm (0.0006 in)
0.050 mm (0.0020 in)
0.010 mm (0.0004 in)
0.050 mm (0.0020 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.050 mm (0.0020 in)
0.5 mm (0.020 in)
91.985 — 91.995 mm (3.6214 — 3.6218 in)
91.975 — 91.985 mm (3.6211 — 3.6214 in)
92.225 — 92.235 mm (3.6309 — 3.6313 in)
92.475 — 92.485 mm (3.6407 — 3.6411 in)
0.004 — 0.008 mm (0.0002 — 0.0003 in)
0.020 mm (0.0008 in)
Piston pin must be fitted into position with thumb at 20°C
(68°F).
ME(H4DOTC)-3
General Description
MECHANICAL
Top ring
Piston ring gap
Oil ring
Piston ring
Clearance between piston
ring and piston ring
groove
Connecting
rod
Second
ring
Top ring
Second
ring
Bend or twist per 100 mm (3.94 in) in
length
Side clearance
Oil clearance
Connecting
rod bearing
Connecting
rod bushing
Thickness at center portion
Clearance between piston pin and
bushing
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
0.20 — 0.25 mm (0.0079 — 0.0098 in)
1.0 mm (0.039 in)
0.40 — 0.50 mm (0.016 — 0.020 in)
1.0 mm (0.039 in)
0.20 — 0.50 mm (0.0079 — 0.020 in)
1.5 mm (0.059 in)
0.04 — 0.08 mm (0.0016 — 0.0031 in)
0.15 mm (0.0059 in)
0.030 — 0.070 mm (0.0012 — 0.0028 in)
0.15 mm (0.0059 in)
Limit
0.10 mm (0.0039 in)
STD
Limit
STD
Limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
ME(H4DOTC)-4
0.070 — 0.330 mm (0.0028 — 0.0130 in)
0.4 mm (0.016 in)
0.020 — 0.046 mm (0.0008 — 0.0018 in)
0.05 mm (0.0020 in)
1.486 — 1.498 mm (0.0585 — 0.0590 in)
1.504 — 1.512 mm (0.0592 — 0.0595 in)
1.514 — 1.522 mm (0.0596 — 0.0599 in)
1.614 — 1.622 mm (0.0635 — 0.0639 in)
0 — 0.022 mm (0 — 0.0009 in)
0.030 mm (0.0012 in)
General Description
MECHANICAL
Bend limit
Crank pin and crank journal
Crank pin outer diameter
Crankshaft
Crank journal outer diameter
Thrust clearance
Oil clearance
Out-of-roundness
Grinding limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05
mm
#1, #3, #5
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
#2, #4
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
STD
#1
Limit
STD
#2
Limit
STD
#3
Limit
STD
#4
Limit
STD
#5
Limit
0.035 mm (0.0014 in)
0.005 mm (0.0002 in) or less
0.25 mm (0.0098 in)
51.984 — 52.000 mm (2.0466 — 2.0472 in)
51.954 — 51.970 mm (2.0454 — 2.0461 in)
51.934 — 51.950 mm (2.0447 — 2.0453 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
59.992 — 60.008 mm (2.3619 — 2.3625 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
59.992 — 60.008 mm (2.3619 — 2.3625 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
ME(H4DOTC)-5
0.030 — 0.115 mm (0.0012 — 0.0045 in)
0.25 mm (0.0098 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.045 mm (0.0018 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.045 mm (0.0018 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
General Description
MECHANICAL
#1, #3
Crankshaft
bearing
Crankshaft bearing thickness
#2, #4, #5
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
1.998 — 2.011 mm (0.0787 — 0.0792 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
2.000 — 2.013 mm (0.0787 — 0.0793 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
2.029 — 2.032 mm (0.0799 — 0.0800 in)
2.129 — 2.132 mm (0.0838 — 0.0839 in)
2. STi MODEL
Type
Valve arrangement
Bore × Stroke
mm (in)
cm3 (cu in)
Piston displacement
Compression ratio
Compression pressure (at 200 — 300
rpm)
Number of piston rings
kPa (kgf/cm2, psi)
Intake valve timing
Max. retard
Min. advance
Max. retard
Min. advance
Closing
Exhaust valve timing
Valve clearance
Opening
Closing
Intake
Exhaust
Idling speed
[At neutral position on MT]
Firing order
Ignition timing
NOTE:
STD: Standard
1,994 (121.67)
8.0
Opening
Engine
Horizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Belt driven, double overhead camshaft, 4-valve/cylinder
92 × 75 (3.62 × 2.95)
I.D.: Inner Diameter
981 — 1,177 (10 — 12, 142 — 171)
Pressure ring: 2, Oil ring: 1
ATDC 6°
BTDC 24°
ABDC 68°
ABDC 38°
BBDC 58°
ATDC 10°
0.20±0.02 (0.0079±0.0008)
0.35±0.02 (0.0138±0.0008)
700±100 (No load)
800±150 (A/C switch ON)
1→3→2→4
12°±10°/700
mm (in)
mm (in)
rpm
BTDC/rpm
O.D.: Outer Diameter
OS: Oversize
ME(H4DOTC)-6
US: Undersize
General Description
MECHANICAL
Belt
tension
adjuster
Protrusion of adjuster rod
5.2 — 6.2 mm (0.205 — 0.244 in)
Spacer O.D.
Tensioner bush I.D.
Belt
tensioner
Clearance between spacer and bush
Side clearance of spacer
STD
Limit
STD
Limit
Bend limit
Thrust clearance
Intake
Cam lobe height
Camshaft
Exhaust
Journal O.D.
STD
Oil clearance
Cylinder
head
Valve seat
Surface warpage limit
Surface grinding limit
Standard height
Refacing angle
Intake
Contacting width
Exhaust
Valve guide
STD
Limit
STD
Limit
Inner diameter
Protrusion above head
Intake
Head edge thickness
Exhaust
Valve
STD
Limit
STD
Limit
STD
Limit
Front
Center
rear
STD
Limit
Stem diameter
Stem oil clearance
STD
Limit
Overall length
STD
Limit
STD
Limit
Intake
Exhaust
Intake
Exhaust
—
Intake
Exhaust
Free length
Squareness
Valve
spring
Set
Tension/spring height
Lift
17.955 — 17.975 mm (0.7069 — 0.7077 in)
18.0 — 18.08 mm (0.7087 — 0.7118 in)
0.025 — 0.125 mm (0.0010 — 0.0049 in)
0.175 mm (0.0069 in)
0.2 — 0.55 mm (0.0079 — 0.0217 in)
0.81 mm (0.0319 in)
0.020 mm (0.0079 in)
0.040 — 0.080 mm (0.0016 — 0.0031 in)
0.10 mm (0.0039 in)
45.25 — 45.35 mm (1.781 — 1.785 in)
45.15 mm (1.758 in)
45.60 — 45.70 mm (1.795 — 1.799 in)
45.50 mm (1.791 in)
37.946 — 37.963 mm (1.4939 — 1.4946 in)
29.946 — 29.963 mm (1.1790 — 1.1796 in)
0.037 — 0.072 mm (0.0015 — 0.0028 in)
0.10 mm (0.0039 in)
0.05 mm (0.0020 in)
0.3 mm (0.012 in)
127.5 mm (5.02 in)
90°
1.0 mm (0.039 in)
1.7 mm (0.067 in)
1.5 mm (0.059 in)
2.2 mm (0.087 in)
6.000 — 6.012 mm (0.2362 — 0.2367 in)
15.8 — 16.2 mm (0.622 — 0.638 in)
1.2 mm (0.047 in)
0.8 mm (0.031 in)
1.5 mm (0.059 in)
0.8 mm (0.031 in)
5.955 — 5.970 mm (0.2344 — 0.2350 in)
5.945 — 5.960 mm (0.2341 — 0.2346 in)
0.030 — 0.057 mm (0.0012 — 0.0022 in)
0.040 — 0.067 mm (0.0016 — 0.0026 in)
0.15 mm (0.0059 in)
104.4 mm (4.110 in)
104.7 mm (4.122 in)
43.89 mm (1.728 in)
2.5°, 1.9 mm (0.075 in)
205 — 237 N (20.9 — 24.2 kgf, 46.1 — 53.3 lb)/
36.0 mm (1.417 in)
553 — 611 N (56.4 — 62.3 kgf, 124 — 137 lb)/
26.45 mm (1.041 in)
ME(H4DOTC)-7
General Description
MECHANICAL
Cylinder
block
Piston
Piston pin
Surface warpage limit (mating with cylinder head)
Surface grinding limit
A
Cylinder bore
STD
B
STD
Taper
Limit
STD
Out-of-roundness
Limit
STD
Piston clearance
Limit
Enlarging (boring) limit
A
STD
B
0.25
mm
(0.0098
in)
Outer diameter
OS
0.50 mm (0.0197 in)
OS
STD
Standard clearance between piston
pin and hole in piston
Limit
Piston ring gap
Oil ring
Piston ring
Clearance between piston
ring and piston ring
groove
Connecting
rod
Second
ring
Top ring
Second
ring
Bend or twist per 100 mm (3.94 in) in
length
Side clearance
Oil clearance
Connecting
rod bearing
Connecting
rod bushing
Thickness at center portion
Clearance between piston pin and
bushing
92.225 — 92.235 mm (3.6309 — 3.6313 in)
92.475 — 92.485 mm (3.6407 — 3.6411 in)
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
0.004 — 0.008 mm (0.0002 — 0.0003 in)
0.020 mm (0.0008 in)
Piston pin must be fitted into position with thumb at 20°C
(68°F).
0.20 — 0.25 mm (0.0079 — 0.0098 in)
1.0 mm (0.039 in)
0.40 — 0.50 mm (0.016 — 0.020 in)
1.0 mm (0.039 in)
0.20 — 0.50 mm (0.0079 — 0.020 in)
1.5 mm (0.059 in)
0.040 — 0.080 mm (0.0016 — 0.0031 in)
0.15 mm (0.0059 in)
0.030 — 0.070 mm (0.0012 — 0.0028 in)
0.15 mm (0.0059 in)
Limit
0.10 mm (0.0039 in)
Degree of fit
Top ring
0.05 mm (0.0020 in)
0.1 mm (0.004 in)
92.005 — 92.015 mm (3.6222 — 3.6226 in)
91.995 — 92.005 mm (3.6218 — 3.6222 in)
0.015 mm (0.0006 in)
0.050 mm (0.0020 in)
0.010 mm (0.0004 in)
0.050 mm (0.0020 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.050 mm (0.0020 in)
0.5 mm (0.020 in)
91.985 — 91.995 mm (3.6214 — 3.6218 in)
91.975 — 91.985 mm (3.6211 — 3.6214 in)
STD
Limit
STD
Limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
ME(H4DOTC)-8
0.070 — 0.330 mm (0.0028 — 0.0130 in)
0.4 mm (0.016 in)
0.020 — 0.046 mm (0.0008 — 0.0018 in)
0.05 mm (0.0020 in)
1.486 — 1.498 mm (0.0585 — 0.0590 in)
1.504 — 1.512 mm (0.0592 — 0.0595 in)
1.514 — 1.522 mm (0.0596 — 0.0599 in)
1.614 — 1.622 mm (0.0635 — 0.0639 in)
0 — 0.022 mm (0 — 0.0009 in)
0.030 mm (0.0012 in)
General Description
MECHANICAL
Bend limit
Crank pin and crank journal
Crank pin outer diameter
Crankshaft
Crank journal outer diameter
Thrust clearance
Oil clearance
Out-of-roundness
Grinding limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05
mm
#1, #3, #5
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
#2, #4
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
STD
#1
Limit
STD
#2
Limit
STD
#3
Limit
STD
#4
Limit
STD
#5
Limit
0.035 mm (0.0014 in)
0.005 mm (0.0002 in) or less
0.25 mm (0.0098 in)
51.984 — 52.000 mm (2.0466 — 2.0472 in)
51.954 — 51.970 mm (2.0454 — 2.0461 in)
51.934 — 51.950 mm (2.0447 — 2.0453 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
59.992 — 60.008 mm (2.3619 — 2.3625 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
59.992 — 60.008 mm (2.3619 — 2.3625 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
ME(H4DOTC)-9
0.030 — 0.115 mm (0.0012 — 0.0045 in)
0.25 mm (0.0098 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.045 mm (0.0018 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.045 mm (0.0018 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
General Description
MECHANICAL
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
#1, #3
Crankshaft
bearing
Crankshaft bearing thickness
#2, #4, #5
1.998 — 2.011 mm (0.0787 — 0.0792 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
2.000 — 2.013 mm (0.0787 — 0.0793 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
2.029 — 2.032 mm (0.0799 — 0.0800 in)
2.129 — 2.132 mm (0.0838 — 0.0839 in)
3. DOHC TURBO MODEL (AUSTRALIA MODEL EXCEPT FOR STi MODEL)
Horizontally opposed, liquid cooled, 4-cylinder,
4-stroke gasoline engine
Belt driven, double overhead camshaft, 4-valve/cylinder
mm (in)
92 × 75 (3.62 × 2.95)
Type
Valve arrangement
Bore × Stroke
cm3 (cu in)
Piston displacement
Compression ratio
Compression pressure (at 200 — 300
rpm)
Number of piston rings
9.0
kPa (kgf/cm2, psi)
Intake valve timing
Closing
Exhaust valve timing
Valve clearance
1,108 — 1,304 (11 — 13, 161 — 189)
Pressure ring: 2, Oil ring: 1
ATDC 7°
BTDC 27°
ABDC 67°
ABDC 33°
BBDC 53°
ATDC 7°
0.20±0.02 (0.0079±0.0008)
0.35±0.02 (0.0138±0.0008)
650±50 (No load)
800±50 (A/C switch ON)
700±50 (No load)
820±50 (A/C switch ON)
1→3→2→4
12°±3°/650
12°±3°/700
Max. retard
Min. advance
Max. retard
Min. advance
Opening
Engine
1,994 (121.67)
Opening
Closing
Intake
Exhaust
mm (in)
mm (in)
MT
Idling speed
[At neutral position on MT, or
“P” or “N” position on AT]
rpm
AT
Firing order
Ignition timing
NOTE:
STD: Standard
BTDC/rpm
I.D.: Inner Diameter
MT
AT
O.D.: Outer Diameter
OS: Oversize
ME(H4DOTC)-10
US: Undersize
General Description
MECHANICAL
Belt
tension
adjuster
Protrusion of adjuster rod
5.2 — 6.2 mm (0.205 — 0.244 in)
Spacer O.D.
Tensioner bush I.D.
Belt
tensioner
Clearance between spacer and bush
Side clearance of spacer
STD
Limit
STD
Limit
Bend limit
Thrust clearance
Intake
Cam lobe height
Camshaft
Exhaust
Journal O.D.
STD
Oil clearance
Cylinder
head
Valve seat
Surface warpage limit
Surface grinding limit
Standard height
Refacing angle
Intake
Contacting width
Exhaust
Valve guide
STD
Limit
STD
Limit
Inner diameter
Protrusion above head
Intake
Head edge thickness
Exhaust
Valve
STD
Limit
STD
Limit
STD
Limit
Front
Center
rear
STD
Limit
Stem diameter
Stem oil clearance
STD
Limit
Overall length
STD
Limit
STD
Limit
Intake
Exhaust
Intake
Exhaust
—
Intake
Exhaust
Free length
Squareness
Valve
spring
Set
Tension/spring height
Lift
17.955 — 17.975 mm (0.7069 — 0.7077 in)
18.0 — 18.08 mm (0.7087 — 0.7118 in)
0.025 — 0.125 mm (0.0010 — 0.0049 in)
0.175 mm (0.0069 in)
0.2 — 0.55 mm (0.0079 — 0.0217 in)
0.81 mm (0.0319 in)
0.020 mm (0.0079 in)
0.040 — 0.080 mm (0.0016 — 0.0031 in)
0.10 mm (0.0039 in)
46.25 — 46.35 mm (1.821 — 1.825 in)
46.15 mm (1.817 in)
46.15 — 46.25 mm (1.817 — 1.821 in)
46.05 mm (1.813 in)
37.946 — 37.963 mm (1.4939 — 1.4946 in)
29.946 — 29.963 mm (1.1790 — 1.1796 in)
0.037 — 0.072 mm (0.0015 — 0.0028 in)
0.10 mm (0.0039 in)
0.05 mm (0.0020 in)
0.3 mm (0.012 in)
127.5 mm (5.02 in)
90°
1.0 mm (0.039 in)
1.7 mm (0.067 in)
1.5 mm (0.059 in)
2.2 mm (0.087 in)
6.000 — 6.012 mm (0.2362 — 0.2367 in)
15.8 — 16.2 mm (0.622 — 0.638 in)
1.2 mm (0.047 in)
0.8 mm (0.031 in)
1.5 mm (0.059 in)
0.8 mm (0.031 in)
5.955 — 5.970 mm (0.2344 — 0.2350 in)
5.945 — 5.960 mm (0.2341 — 0.2346 in)
0.030 — 0.057 mm (0.0012 — 0.0022 in)
0.040 — 0.067 mm (0.0016 — 0.0026 in)
0.15 mm (0.0059 in)
104.4 mm (4.110 in)
104.7 mm (4.122 in)
47.32 mm (1.8630 in)
2.5°, 2.1 mm (0.083 in)
205 — 235 N (20.9 — 24.0 kgf, 46.1 — 52.8 lb)/
36.0 mm (1.417 in)
426 — 490 N (43.4 — 50.0 kgf, 95.8 — 110 lb)/
26.5 mm (1.043 in)
ME(H4DOTC)-11
General Description
MECHANICAL
Cylinder
block
Piston
Piston pin
Surface warpage limit (mating with cylinder head)
Surface grinding limit
A
Cylinder bore
STD
B
STD
Taper
Limit
STD
Out-of-roundness
Limit
STD
Piston clearance
Limit
Enlarging (boring) limit
A
STD
B
0.25
mm
(0.0098
in)
Outer diameter
OS
0.50 mm (0.0197 in)
OS
STD
Standard clearance between piston
pin and hole in piston
Limit
Piston ring gap
Oil ring
Piston ring
Clearance between piston
ring and piston ring
groove
Connecting
rod
Second
ring
Top ring
Second
ring
Bend or twist per 100 mm (3.94 in) in
length
Side clearance
Oil clearance
Connecting
rod bearing
Connecting
rod bushing
Thickness at center portion
Clearance between piston pin and
bushing
92.225 — 92.235 mm (3.6309 — 3.6313 in)
92.475 — 92.485 mm (3.6407 — 3.6411 in)
STD
Limit
STD
Limit
STD
Limit
STD
Limit
STD
Limit
0.004 — 0.008 mm (0.0002 — 0.0003 in)
0.020 mm (0.0008 in)
Piston pin must be fitted into position with thumb at 20°C
(68°F).
0.20 — 0.25 mm (0.0079 — 0.0098 in)
1.0 mm (0.039 in)
0.40 — 0.50 mm (0.016 — 0.020 in)
1.0 mm (0.039 in)
0.20 — 0.50 mm (0.0079 — 0.020 in)
1.5 mm (0.059 in)
0.040 — 0.080 mm (0.0016 — 0.0031 in)
0.15 mm (0.0059 in)
0.030 — 0.070 mm (0.0012 — 0.0028 in)
0.15 mm (0.0059 in)
Limit
0.10 mm (0.0039 in)
Degree of fit
Top ring
0.05 mm (0.0020 in)
0.1 mm (0.004 in)
92.005 — 92.015 mm (3.6222 — 3.6226 in)
91.995 — 92.005 mm (3.6218 — 3.6222 in)
0.015 mm (0.0006 in)
0.050 mm (0.0020 in)
0.010 mm (0.0004 in)
0.050 mm (0.0020 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.050 mm (0.0020 in)
0.5 mm (0.020 in)
91.985 — 91.995 mm (3.6214 — 3.6218 in)
91.975 — 91.985 mm (3.6211 — 3.6214 in)
STD
Limit
STD
Limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
0.070 — 0.330 mm (0.0028 — 0.0130 in)
0.4 mm (0.016 in)
0.020 — 0.046 mm (0.0008 — 0.0018 in)
0.05 mm (0.0020 in)
1.486 — 1.498 mm (0.0585 — 0.0590 in)
1.504 — 1.512 mm (0.0592 — 0.0595 in)
1.514 — 1.522 mm (0.0596 — 0.0599 in)
1.614 — 1.622 mm (0.0635 — 0.0639 in)
ME(H4DOTC)-12
0 — 0.022 mm (0 — 0.0009 in)
0.030 mm (0.0012 in)
General Description
MECHANICAL
Bend limit
Crank pin and crank journal
Crank pin outer diameter
Crankshaft
Crank journal outer diameter
Thrust clearance
Oil clearance
Out-of-roundness
Grinding limit
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05
mm
#1, #3, #5
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
#2, #4
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
Limit
STD
#1
Limit
STD
#2
Limit
STD
#3
Limit
STD
#4
Limit
STD
#5
Limit
0.035 mm (0.0014 in)
0.005 mm (0.0002 in) or less
0.25 mm (0.0098 in)
51.984 — 52.000 mm (2.0466 — 2.0472 in)
51.954 — 51.970 mm (2.0454 — 2.0461 in)
51.934 — 51.950 mm (2.0447 — 2.0453 in)
51.734 — 51.750 mm (2.0368 — 2.0374 in)
59.992 — 60.008 mm (2.3619 — 2.3625 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
59.992 — 60.008 mm (2.3619 — 2.3625 in)
59.962 — 59.978 mm (2.3607 — 2.3613 in)
59.942 — 59.958 mm (2.3599 — 2.3605 in)
59.742 — 59.758 mm (2.3520 — 2.3527 in)
0.030 — 0.115 mm (0.0012 — 0.0045 in)
0.25 mm (0.0098 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.045 mm (0.0018 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.045 mm (0.0018 in)
0.010 — 0.030 mm (0.0004 — 0.0012 in)
0.040 mm (0.0016 in)
ME(H4DOTC)-13
General Description
MECHANICAL
#1, #3
Crankshaft
bearing
Crankshaft bearing thickness
#2, #4, #5
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
STD
0.03 mm
(0.0012
in) US
0.05 mm
(0.0020
in) US
0.25 mm
(0.0098
in) US
1.998 — 2.011 mm (0.0787 — 0.0792 in)
2.017 — 2.020 mm (0.0794 — 0.0795 in)
2.027 — 2.030 mm (0.0798 — 0.0799 in)
2.127 — 2.130 mm (0.0837 — 0.0839 in)
2.000 — 2.013 mm (0.0787 — 0.0793 in)
2.019 — 2.022 mm (0.0795 — 0.0796 in)
2.029 — 2.032 mm (0.0799 — 0.0800 in)
2.129 — 2.132 mm (0.0838 — 0.0839 in)
ME(H4DOTC)-14
General Description
MECHANICAL
B: COMPONENT
1. TIMING BELT
• EXCEPT FOR STi AND AUSTRALIA MODEL
(2)
(1)
(2)
T7
T2
(3)
T1
(2)
(4)
T2
(5)
T1
T3
(6)
(12)
(9)
(7)
(8)
T1
(14)
T5
T4
T4
T1
T4
(2)
(10)
(14)
T2
(11)
T4
(17)
(13)
T5
T1
(15)
(16)
T6
(18)
T1
ME-00601
(1)
(2)
(3)
(4)
(5)
(6)
Timing belt cover No. 2 (RH)
Timing belt guide (MT model)
Crankshaft sprocket
Timing belt cover No. 2 (LH)
Tensioner bracket
Automatic belt tension adjuster
ASSY
(7)
(8)
(9)
Belt idler
Exhaust camshaft sprocket (RH)
Intake camshaft sprocket (RH)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Intake camshaft sprocket (LH)
Exhaust camshaft sprocket (LH)
Timing belt
Belt idler No. 2
Belt idler
Timing belt cover (LH)
Front belt cover
Timing belt cover (RH)
Crankshaft pulley
Tightening torque: N·m (kgf-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 25 (2.5, 18.1)
T4: 39 (4.0, 28.9)
T5: 98 (10, 72.4)
T6: <Ref. to ME(H4DOTC)-56,
INSTALLATION, CRANKSHAFT
PULLEY.>
T7: 10 (1.0, 7.2)
ME(H4DOTC)-15
General Description
MECHANICAL
• STi AND AUSTRALIA MODEL
(2)
(1)
(2)
T2
T2
(3)
T1
(2)
(4)
T2
(5)
T1
T3
(9)
(12)
(6)
T5
(7)
(8)
T4
T3
(14)
T1
T5
T1
T5
T4
(2)
(10)
(14)
T2
(11)
T4
(17)
(13)
T5
T1
(15)
(16)
T6
(18)
T1
ME-00704
(1)
(2)
(3)
(4)
(5)
(6)
Timing belt cover No. 2 (RH)
Timing belt guide
Crankshaft sprocket
Timing belt cover No. 2 (LH)
Tensioner bracket
Automatic belt tension adjuster
ASSY
(7)
(8)
(9)
Belt idler
Exhaust camshaft sprocket (RH)
Intake camshaft sprocket (RH)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Intake camshaft sprocket (LH)
Exhaust camshaft sprocket (LH)
Timing belt
Belt idler No. 2
Belt idler
Timing belt cover (LH)
Front belt cover
Timing belt cover (RH)
Crankshaft pulley
ME(H4DOTC)-16
Tightening torque: N·m (kgf-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 25 (2.5, 18.1)
T4: 39 (4.0, 28.9)
T5: 98 (10, 72.4)
T6: <Ref. to ME(H4DOTC)-56,
INSTALLATION, CRANKSHAFT
PULLEY.>
General Description
MECHANICAL
2. CYLINDER HEAD AND CAMSHAFT
• EXCEPT FOR STi AND AUSTRALIA MODEL
T4
T2
(3)
(4)
(2)
(1)
T3
(6) (7)
(8)
(5)
T1
T5
(10)
(13)
(11)
(15)
T3
(16)
(12)
T5
(9)
(14)
(16)
(32)
(17)
(28)
(29)
(30)
T1
T4
(13)
T4
(22)
(21)
T3
(3)
(14)
(25)
(24)
(32)
(18)
(20)
(31)
(4)
T3
T5
T2
(19)
(23)
(26)
T5
T2
(27)
ME(H4DOTC)-17
ME-00756
General Description
MECHANICAL
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Rocker cover (RH)
Rocker cover gasket (RH)
Oil separator cover
Gasket
Intake camshaft cap (Front RH)
Intake camshaft cap (Center RH)
Intake camshaft cap (Rear RH)
Intake camshaft cap (RH)
Exhaust camshaft cap (Front RH)
Exhaust camshaft cap (Center
RH)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
Cylinder head (RH)
Cylinder head gasket
Cylinder head (LH)
Intake camshaft (LH)
Exhaust camshaft (LH)
Intake camshaft cap (Front LH)
Intake camshaft cap (Center LH)
Intake camshaft cap (Rear LH)
Exhaust camshaft cap (Front LH)
Exhaust camshaft cap (Center
LH)
(11)
(12)
(13)
(14)
Exhaust camshaft cap (Rear RH)
Exhaust camshaft (RH)
Cylinder head bolt
Oil seal
(25)
(26)
(27)
(28)
Exhaust camshaft cap (Rear LH)
Rocker cover gasket (LH)
Rocker cover (LH)
Oil filler cap
ME(H4DOTC)-18
(29)
(30)
(31)
(32)
Gasket
Oil filler duct
O-ring
Stud bolt
Tightening torque: N·m (kgf-m, ft-lb)
T1: <Ref. to ME(H4DOTC)-78,
INSTALLATION, CYLINDER
HEAD ASSEMBLY.>
T2:
T3:
T4:
T5:
5 (0.5, 3.6)
20 (2.0, 14.5)
6.4 (0.65, 4.7)
10 (1.0, 7.2)
General Description
MECHANICAL
• STi AND AUSTRALIA MODEL
T2
(2)
T5
(1)
(4)
(5)
T1
T5
T3
(10)
(8)
(3)
(12)
(13)
T3
(7)
(6)
(9)
(11)
(13)
(28)
(14)
(24)
(25)
(26)
(10)
(18)
(17)
T4
T5
(11)
(27)
(22)
(21)
(28)
(20)
T2
(15)
(16)
T3
T3
(19)
T5
T2
(23)
ME-00705
ME(H4DOTC)-19
General Description
MECHANICAL
(1)
(2)
(3)
Rocker cover (RH)
Rocker cover gasket (RH)
Oil flow control solenoid valve
assembly (RH)
(4)
(5)
(6)
(7)
Intake camshaft cap (RH)
Intake camshaft (RH)
Exhaust camshaft cap (Front RH)
Exhaust camshaft cap (Center
RH)
Exhaust camshaft cap (Rear RH)
Exhaust camshaft (RH)
Cylinder head bolt
Oil seal
Cylinder head (RH)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
Cylinder head gasket
Cylinder head (LH)
Intake camshaft (LH)
Exhaust camshaft (LH)
Oil flow control solenoid valve
assembly (LH)
(18)
(19)
(20)
Intake camshaft cap (LH)
Exhaust camshaft cap (Front LH)
Exhaust camshaft cap (Center
LH)
Exhaust camshaft cap (Rear LH)
Rocker cover gasket (LH)
Rocker cover (LH)
Oil filler cap
(21)
(22)
(23)
(24)
ME(H4DOTC)-20
(25)
(26)
(27)
(28)
Gasket
Oil filler duct
O-ring
Stud bolt
Tightening torque: N·m (kgf-m, ft-lb)
T1: <Ref. to ME(H4DOTC)-78,
INSTALLATION, CYLINDER
HEAD ASSEMBLY.>
T2:
T3:
T4:
T5:
5 (0.5, 3.6)
10 (1.0, 7)
6.4 (0.65, 4.7)
20 (2.0, 14.5)
General Description
MECHANICAL
3. CYLINDER HEAD AND VALVE ASSEMBLY
(11)
(1)
(4)
(5)
(6)
(7)
(8)
(9)
(3)
(2)
(11)
(4)
(5)
(6)
(7)
(8)
(9)
(12)
(4)
(10)
(6)
(12)
(7)
(8)
(4)
(9)
(10)
(6)
(7)
(8)
(9)
ME-00003
(1)
(2)
(3)
(4)
Exhaust valve
Intake valve
Cylinder head
Valve spring seat
(5)
(6)
(7)
(8)
Intake valve oil seal
Valve spring
Retainer
Retainer key
ME(H4DOTC)-21
(9)
(10)
(11)
(12)
Valve lifter
Exhaust valve oil seal
Intake valve guide
Exhaust valve guide
General Description
MECHANICAL
4. CYLINDER BLOCK
T2
T6
T8
T2
T10
(1)
T5
(6)
T2
(7)
T4
(2)
(8)
(3)
T2
(5)
(4)
(10)
(9)
T2
T6
(10)
(14)
(11)
(4)
(10)
(3)
T2
T4
(3)
(10)
(4)
(27)
(12)
T6
(10)
(15)
(16)
(19)
(18)
T2
T2
(20)
(25)
T2
T3
T5
(17)
T11
T7
(13)
(26)
T1
(23)
(24)
T9
(21)
(22)
T1
ME-00725
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
Oil pressure switch
Cylinder block (RH)
Service hole plug
Gasket
Oil separator cover
Water by-pass pipe
Oil pump
Front oil seal
Rear oil seal
O-ring
Service hole cover
Cylinder block (LH)
Water pump
Baffle plate
Oil cooler
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Water by-pass pipe
Connector
Oil strainer
Gasket
Oil pan
Drain plug
Metal gasket
Oil level gauge guide
Oil filter
Gasket
Water pump hose
Plug
ME(H4DOTC)-22
Tightening torque: N·m (kgf-m, ft-lb)
T1: 5 (0.5, 3.6)
T2: 6.4 (0.65, 4.7)
T3: 10 (1.0, 7.2)
T4: 25 (2.5, 18.1)
T5: <Ref. to ME(H4DOTC)-89,
INSTALLATION, CYLINDER
BLOCK.>
T6: 69 (7.0, 50.6)
T7: First 12 (1.2, 8.7)
Second 12 (1.2, 8.7)
T8:
T9:
T10:
T11:
16 (1.6, 11.6)
44 (4.5, 33)
25 (2.5, 18.1)
54 (5.5, 40)
General Description
MECHANICAL
5. CRANKSHAFT AND PISTON
(1)
T2
(2)
(4)
T2
(10)
(9)
(11)
(5)
(3)
(12)
(6)
(7)
(13)
(10)
(8)
(15)
(14)
(13)
(14)
(13)
T1
(10)
(13)
(16)
(8)
(12)
(19) (11)
(17)
(18)
(18)
(17)
(10)
(9)
(7)
(6)
(5)
ME-00005
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Flywheel (MT model)
Ball bearing (MT model)
Reinforcement (AT model)
Drive plate (AT model)
Top ring
Second ring
Oil ring
Piston
Piston pin
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Circlip
Connecting rod bolt
Connecting rod
Connecting rod bearing
Connecting rod cap
Crankshaft
Woodruff key
Crankshaft bearing #1, #3
Crankshaft bearing #2, #4
ME(H4DOTC)-23
(19)
Crankshaft bearing #5
Tightening torque: N·m (kgf-m, ft-lb)
T1: 45 (4.6, 33.3) (Except for STi
model)
T1: 52 (5.3, 38.4) (STi model)
T2: 72 (7.3, 52.8) (Except for STi
model)
T2: 77 (7.9, 56.8) (STi model)
General Description
MECHANICAL
6. ENGINE MOUNTING
T2
(3)
T2
(3)
T1
(2)
(2)
(1)
T1
T3
T3
ME-00706
(1)
(2)
Heat shield cover
Front cushion rubber
(3)
Front engine mounting bracket
ME(H4DOTC)-24
Tightening torque: N·m (kgf-m, ft-lb)
T1: 35 (3.6, 25.8)
T2: 42 (4.3, 30.9)
T3: 85 (8.7, 62.7)
General Description
MECHANICAL
C: CAUTION
• Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
• Remove contamination including dirt and corrosion before removal, installation or disassembly.
• Keep the disassembled parts in order and protect them from dust or dirt.
• Before removal, installation or disassembly, be
sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
• Be careful not to burn your hands, because each
part in the vehicle is hot after running.
• Be sure to tighten fasteners including bolts and
nuts to the specified torque.
• Place shop jacks or safety stands at the specified
points.
• Before disconnecting electrical connectors of
sensors or units, be sure to disconnect the ground
cable from battery.
• All parts should be thoroughly cleaned, paying
special attention to the engine oil passages, pistons and bearings.
• Rotating parts and sliding parts such as piston,
bearing and gear should be coated with oil prior to
assembly.
• Be careful not to let oil, grease or coolant contact
the timing belt, clutch disc and flywheel.
• All removed parts, if to be reused, should be reinstalled in the original positions and directions.
• Bolts, nuts and washers should be replaced with
new ones as required.
• Even if necessary inspections have been made
in advance, proceed with assembly work while
making rechecks.
• Remove or install the engine in an area where
chain hoists, lifting devices, etc. are available for
ready use.
• Be sure not to damage coated surfaces of body
panels with tools or stain seats and windows with
coolant or oil. Place a cover over fenders, as required, for protection.
• Prior to starting work, prepare the following:
Service tools, clean cloth, containers to catch coolant and oil, wire ropes, chain hoist, transmission
jacks, etc.
• Lift-up or lower the vehicle when necessary.
Make sure to support the correct positions.
ME(H4DOTC)-25
General Description
MECHANICAL
D: PREPARATION TOOL
1. SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
498267600
DESCRIPTION
CYLINDER
HEAD TABLE
REMARKS
• Used for replacing valve guides.
• Used for removing and installing valve springs.
498457000
ENGINE STAND
ADAPTER RH
Used with ENGINE STAND (499817000).
498457100
ENGINE STAND
ADAPTER LH
Used with ENGINE STAND (499817000).
498497100
CRANKSHAFT
STOPPER
Used for stopping rotation of flywheel when loosening and tightening crankshaft pulley bolt, etc.
ST-498267600
ST-498457000
ST-498457100
ST-498497100
ME(H4DOTC)-26
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
398744300
DESCRIPTION
PISTON GUIDE
REMARKS
Used for installing piston in cylinder for 2.0 L
engine.
498857100
VALVE OIL SEAL
GUIDE
Used for press-fitting of intake and exhaust valve
guide oil seals.
499017100
PISTON PIN
GUIDE
Used for installing piston pin, piston and connecting rod.
499037100
CONNECTING
ROD BUSHING
REMOVER &
INSTALLER
Used for removing and installing connecting rod
bushing.
ST-398744300
ST-498857100
ST-499017100
ST-499037100
ME(H4DOTC)-27
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499097600
DESCRIPTION
PISTON PIN
REMOVER
ASSY
REMARKS
Used for removing piston pin. (Except for Australia
model)
499097700
PISTON PIN
REMOVER
ASSY
Used for removing piston pin. (Australia model
except for STi model)
499207400
CAMSHAFT
SPROCKET
WRENCH
Used for removing and installing exhaust camshaft sprocket and intake camshaft sprocket (RH).
(Except for STi and Australia model)
18231AA010
CAMSHAFT
SPROCKET
WRENCH
Used for removing and installing intake camshaft
sprocket (LH). (Except for STi and Australia
model)
ST-499097600
ST-499097700
ST-499207400
ST18231AA010
ME(H4DOTC)-28
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499977500
DESCRIPTION
CAMSHAFT
SPROCKET
WRENCH
REMARKS
Used for removing and installing intake camshaft
sprocket. (STi and Australia model)
499587200
CRANKSHAFT
OIL SEAL
INSTALLER
• Used for installing crankshaft oil seal.
• Used with CRANKSHAFT OIL SEAL GUIDE
(499597100).
499597100
CRANKSHAFT
• Used for installing crankshaft oil seal.
OIL SEAL GUIDE • Used with CRANKSHAFT OIL SEAL
INSTALLER (499587200).
499718000
VALVE SPRING
REMOVER
ST-499977500
ST-499587200
ST-499597100
ST-499718000
ME(H4DOTC)-29
Used for removing and installing valve spring.
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
18251AA020
DESCRIPTION
VALVE GUIDE
ADJUSTER
REMARKS
Used for installing intake and exhaust valve
guides.
499767200
VALVE GUIDE
REMOVER
Used for removing valve guides.
499767400
VALVE GUIDE
REAMER
Used for reaming valve guides.
499817000
ENGINE STAND
• Stand used for engine disassembly and assembly.
• Used with ENGINE STAND ADAPTER RH
(498457000) & LH (498457100).
ST18251AA020
ST-499767200
ST-499767400
ST-499817000
ME(H4DOTC)-30
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499977400
DESCRIPTION
CRANKSHAFT
PULLEY
WRENCH
REMARKS
Used for stopping rotation of crankshaft pulley
when loosening and tightening crankshaft pulley
bolts.
499987500
CRANKSHAFT
SOCKET
Used for rotating crankshaft.
498547000
OIL FILTER
WRENCH
• Used for removing and installing oil filter.
• For oil filter (Outer diameter: 80 mm (3.15 in))
18332AA000
OIL FILTER
WRENCH
• Used for removing and installing oil filter.
• For oil filter (Outer diameter: 68 mm (2.68 in))
ST-499977400
ST-499987500
ST-498547000
ST18332AA000
ME(H4DOTC)-31
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
499587100
DESCRIPTION
OIL SEAL
INSTALLER
REMARKS
Used for installing oil pump oil seal.
499587600
OIL SEAL
INSTALLER
Used for installing camshaft oil seal for DOHC
engine.
499597200
OIL SEAL GUIDE Used for installing camshaft oil seal for DOHC
engine.
Used with OIL SEAL GUIDE (499587600).
498277200
STOPPER SET
ST-499587100
ST-499587600
ST-499597200
ST-498277200
ME(H4DOTC)-32
Used for installing automatic transmission assembly to engine.
General Description
MECHANICAL
ILLUSTRATION
TOOL NUMBER
24082AA230
DESCRIPTION
CARTRIDGE
REMARKS
Troubleshooting for electrical systems.
22771AA030
SUBARU
SELECT MONITOR KIT
Troubleshooting for electrical systems.
• English: 22771AA030 (Without printer)
• German: 22771AA070 (Without printer)
• French: 22771AA080 (Without printer)
• Spanish: 22771AA090 (Without printer)
ST24082AA230
ST22771AA030
2. GENERAL PURPOSE TOOLS
TOOL NAME
Compression Gauge
REMARKS
Used for measuring compression.
E: PROCEDURE
It is possible to conduct the following service procedures with engine on the vehicle, however, the procedures
described in this section are based on the condition that the engine is removed from the vehicle.
• V-belt
• Timing Belt
• Camshaft
• Cylinder Head
ME(H4DOTC)-33
Compression
MECHANICAL
2. Compression
A: INSPECTION
CAUTION:
After warming-up, engine becomes very hot. Be
careful not to burn yourself during measurement.
1) After warming-up the engine, turn the ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Release the fuel pressure. <Ref. to
FU(H4DOTC)-53, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
4) Remove all the spark plugs. <Ref. to
IG(H4DOTC)-4, REMOVAL, Spark Plug.>
5) Fully open the throttle valve.
6) Check the starter motor for satisfactory performance and operation.
7) Hold the compression gauge tight against spark
plug hole.
Australia model (Except for STi model)
Standard
1.108 — 1,304 kPa (11 — 13 kgf/cm2, 161 —
189 psi)
Limit
951 kPa (10 kgf/cm2, 138 psi)
Difference between cylinders
Less than 49 kPa (0.5 kgf/cm2, 7 psi)
NOTE:
When using a screw-in type compression gauge,
the screw (put into cylinder head spark plug hole)
should be less than 18 mm (0.71 in) long.
8) Crank the engine by means of starter motor, and
then read the maximum value on the gauge when
the pointer is steady.
ME-00007
9) Perform at least two measurements per cylinder,
and make sure that the values are correct.
Compression (350 rpm and fully open throttle):
Except for Australia model
Standard
981 — 1,177 kPa (10 — 12 kgf/cm2, 142 —
171 psi)
Limit
882 kPa (9.0 kgf/cm2, 128 psi)
Difference between cylinders
Less than 49 kPa (0.5 kgf/cm2, 7 psi)
ME(H4DOTC)-34
Idle Speed
MECHANICAL
3. Idle Speed
A: INSPECTION
1. USING SUBARU SELECT MONITOR
1) Before checking the idle speed, check the following:
(1) Ensure the air cleaner element is free from
clogging, ignition timing is correct, spark plugs
are in good condition, and that the hoses are
connected properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Warm-up the engine.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to SUBARU SELECT MONITOR.
5) Connect the SUBARU SELECT MONITOR to
data link connector.
6) Turn the ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
7) Select the {2. Each System Check} in Main
Menu.
8) Select the {Engine Control System} in Selection
Menu.
9) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
10) Select the {1.12 Data Display} in Data Display
Menu.
11) Start the engine, and then read the engine idle
speed.
12) Check the idle speed when unloaded. (With
headlights, heater fan, rear defroster, radiator fan,
air conditioning, etc. OFF)
NOTE:
As idle speed is controlled by the automatic adjustment type, it can not be adjusted manually. If the
idle speed is out of specifications, refer to General
On-board Diagnosis Table under “Engine Control
System”. <Ref. to EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
Idle speed [No load and gears in neutral]:
Except for Australia model
700±100 rpm
Australia model (Except for STi model)
650±50 rpm (MT model)
700±50 rpm (AT model)
13) Check the idle speed when loaded. (Turn the
air conditioning switch to “ON” and operate the
compressor for at least 1 minute before measurement.)
Idle speed [A/C “ON”, no load and gears in neutral]:
Except for Australia model
800±150 rpm
Australia model (Except for STi model)
800±50 rpm (MT model)
820±50 rpm (AT model)
ME(H4DOTC)-35
Ignition Timing
MECHANICAL
4. Ignition Timing
A: INSPECTION
1. USING SUBARU SELECT MONITOR
1) Before checking the ignition timing speed, check
the following:
(1) Ensure the air cleaner element is free from
clogging, spark plugs are in good condition, and
that hoses are connected properly.
(2) Ensure the malfunction indicator light does
not illuminate.
2) Warm-up the engine.
3) Stop the engine, and then turn the ignition switch
to OFF.
4) Insert the cartridge to SUBARU SELECT MONITOR.
5) Connect the SUBARU SELECT MONITOR to
data link connector.
6) Turn the ignition switch to ON, and SUBARU
SELECT MONITOR switch to ON.
7) Select the {2. Each System Check} in Main
Menu.
8) Select the {Engine Control System} in Selection
Menu.
9) Select the {1. Current Data Display & Save} in
Engine Control System Diagnosis.
10) Select the {1.12 Data Display} in Data Display
Menu.
11) Start the engine and check the ignition timing at
idle speed.
Ignition timing [BTDC/rpm]:
Except for Australia model
12°±10°/700
Australia model (Except for STi model)
12°±3°/650 (MT model)
12°±3°/700 (AT model)
If the timing is not correct, check the ignition control
system. Refer to Engine Control System. <Ref. to
EN(H4DOTC)(diag)-2, Basic Diagnostic Procedure.>
ME(H4DOTC)-36
Intake Manifold Vacuum
MECHANICAL
5. Intake Manifold Vacuum
A: INSPECTION
1) Warm-up the engine.
2) Disconnect the brake vacuum hose, and then install the vacuum gauge to hose fitting on manifold.
3) Keep the engine at the idle speed, and then read the vacuum gauge indication.
By observing the gauge needle movement, the internal condition of engine can be diagnosed as described
below.
ME-00008
Vacuum pressure (at idling, A/C “OFF”):
Less than −60.0 kPa (−450 mmHg, −17.72 inHg)
Diagnosis of engine condition by measurement of manifold vacuum
Vacuum gauge indication
Possible engine condition
1. Needle is steady but lower than normal position. This tenLeakage around intake manifold gasket or disconnection or
dency becomes more evident as engine temperature rises.
damaged vacuum hose
2. When engine speed is reduced slowly from higher speed,
Back pressure too high, or exhaust system clogged
needle stops temporarily when it is lowering or becomes steady
above normal position.
3. Needle intermittently drops to position lower than normal
Leakage around cylinder
position.
4. Needle drops suddenly and intermittently from normal posiSticky valves
tion.
5. When engine speed is gradually increased, needle begins to Weak or broken valve springs
vibrate rapidly at certain speed, and then vibration increases as
engine speed increases.
6. Needle vibrates above and below normal position in narrow
Defective ignition system or throttle chamber idle adjustment
range.
ME(H4DOTC)-37
Engine Oil Pressure
MECHANICAL
6. Engine Oil Pressure
A: INSPECTION
1) Remove the oil pressure switch from engine cylinder block. <Ref. to LU(H4DOTC)-18, REMOVAL,
Oil Pressure Switch.>
2) Connect the oil pressure gauge hose to cylinder
block.
3) Connect the battery ground cable to battery.
FU-00009
4) Start the engine, and then measure the oil pressure.
ME-00009
Oil pressure:
98 kPa (1.0 kg/cm2, 14 psi) or more at 800 rpm
294 kPa (3.0 kg/cm2, 43 psi) or more at 5,000
rpm
• If the oil pressure is out of specification, check oil
pump, oil filter and lubrication line. <Ref. to
LU(H4DOTC)-21, INSPECTION, Engine Lubrication System Trouble in General.>
• If the oil pressure warning light is turned ON and
oil pressure is in specification, replace the oil pressure switch. <Ref. to LU(H4DOTC)-21, INSPECTION, Engine Lubrication System Trouble in
General.>
NOTE:
The specified data is based on an engine oil temperature of 80°C (176°F).
5) After measuring the oil pressure, install the oil
pressure switch. <Ref. to LU(H4DOTC)-18, INSTALLATION, Oil Pressure Switch.>
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
ME(H4DOTC)-38
Fuel Pressure
MECHANICAL
7. Fuel Pressure
A: INSPECTION
6) Measure the fuel pressure while disconnecting
the pressure regulator vacuum hose from intake
manifold.
CAUTION:
Before removing the fuel pressure gauge, release the fuel pressure.
Fuel pressure:
Standard; 284 — 314 kPa (2.9 — 3.2 kgf/cm2,
41 — 46 psi)
NOTE:
If out of specification, check or replace the pressure
regulator and pressure regulator vacuum hose.
1) Release the fuel pressure. <Ref. to
FU(H4DOTC)-53, RELEASING OF FUEL PRESSURE, OPERATION, Fuel.>
2) Open the fuel flap lid, and then remove the fuel
filler cap.
3) Disconnect the fuel delivery hoses from fuel filter, and then connect the fuel pressure gauge.
ME-00011
7) After connecting the pressure regulator vacuum
hose, measure the fuel pressure.
Fuel pressure:
Standard; 230 — 260 kPa (2.35 — 2.65
kgf/cm2, 33 — 38 psi)
ME-00010
4) Connect the connector of fuel pump relay.
ME-00011
NOTE:
The fuel pressure gauge registers 10 to 20 kPa (0.1
to 0.2 kgf/cm2, 1 to 3 psi) higher than standard values during high-altitude operations.
FU-00871
5) Start the engine.
ME(H4DOTC)-39
Valve Clearance
MECHANICAL
8. Valve Clearance
10) When inspecting the #2 and #4 cylinders:
(1) Disconnect the battery cable, and then remove the battery and battery carrier.
A: INSPECTION
Inspection and adjustment of the valve clearance
should be performed while engine is cold.
1) Set the vehicle on a lift.
2) Disconnect the ground cable from battery.
ME-00013
(2) Remove the bolt which secures the engine
harness bracket onto body.
FU-00009
3) Remove the air intake duct. <Ref. to
IN(H4DOTC)-8, REMOVAL, Air Intake Duct.>
4) Remove the bolts which secure the timing belt
cover (RH).
5) Lift-up the vehicle.
6) Remove the under cover.
7) Loosen the remaining bolts which secure the
timing belt cover (RH), and then remove the timing
belt cover.
8) Lower the vehicle.
9) When inspecting the #1 and #3 cylinders:
(1) Pull out the engine harness connector with
bracket from air cleaner upper cover.
ME-00014
(3) Disconnect the washer motor connectors.
ME-00015
(4) Remove the washer tank mounting bolts.
ME-00012
(2) Remove the air cleaner case. <Ref. to
IN(H4DOTC)-7, REMOVAL, Air Cleaner.>
(3) Disconnect the ignition coil connector.
(4) Remove the ignition coil.
(5) Place a suitable container under the vehicle.
(6) Disconnect the PCV hose from rocker cover
(RH).
(7) Remove the bolts, and then remove the
rocker cover (RH).
ME(H4DOTC)-40
ME-00016
Valve Clearance
MECHANICAL
(5) Move the washer tank upward.
NOTE:
If the measured value is not within specification,
take notes of the value in order to adjust the valve
clearance later on.
(A)
ME-00017
(6) Disconnect the ignition coil connector.
(7) Remove the ignition coil.
(8) Place a suitable container under the vehicle.
(9) Disconnect the PCV hose from rocker cover
(LH).
(10)Remove the bolts, and then remove the
rocker cover (LH).
11) Turn the crankshaft pulley clockwise until arrow
mark on the camshaft sprocket is set to position
shown in the figure.
NOTE:
Turn the crankshaft using socket wrench.
ME-00019
13) If necessary, adjust the valve clearance. <Ref.
to ME(H4DOTC)-42, ADJUSTMENT, Valve Clearance.>
14) Further turn the crankshaft pulley clockwise.
Using the same procedures described previously,
and then measure the valve clearances again.
(1) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #2 cylinder exhaust valve and #3 cylinder intake valve clearances.
ME-00733
ME-00734
12) Measure the #1 cylinder intake valve and #3
cylinder exhaust valve clearance by using thickness gauge (A).
NOTE:
• Insert the thickness gauge in as horizontal a direction as possible with respect to the shim.
• Measure the exhaust valve clearances while lifting-up the vehicle.
(2) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #2 cylinder intake valve and #4 cylinder exhaust valve clearances.
Valve clearance:
Intake: 0.20±0.02 mm (0.0079±0.0008 in)
Exhaust: 0.35±0.02 mm (0.0138±0.0008 in)
ME-00735
ME(H4DOTC)-41
Valve Clearance
MECHANICAL
(3) Set the arrow mark on camshaft sprocket to
position shown in the figure, and then measure
the #1 cylinder exhaust valve and #4 cylinder intake valve clearances.
3) Remove the valve lifter.
4) Measure the thickness of valve lifter with a micrometer.
ME-00025
ME-00736
15) After inspection, install the related parts in the
reverse order of removal.
Tightening torque:
33 N·m (3.4 kgf-m, 25 ft-lb)
5) Select a shim of suitable thickness using measured valve clearance and valve lifter thickness, by
referring to the following table.
Unit: mm
Intake valve: S = V – 0.20
Exhaust valve: S = V – 0.25
S: Valve lifter thickness to be used
V: Measured valve clearance
ME-00023
B: ADJUSTMENT
CAUTION:
Adjustment of the valve clearance should be
performed while engine is cold.
1) Measure all valve clearances. <Ref. to
ME(H4DOTC)-40, INSPECTION, Valve Clearance.>
NOTE:
Record each valve clearance after it has been
measured.
ME-00024
2) Remove the camshaft. <Ref. to ME(H4DOTC)69, REMOVAL, Camshaft.>
Part No.
13228 AB101
13228 AB111
13228 AB121
13228 AB131
13228 AB141
13228 AB151
13228 AB161
13228 AB171
13228 AB181
13228 AB191
13228 AB201
13228 AB211
13228 AB221
13228 AB231
13228 AB241
13228 AB251
13228 AB261
13228 AB271
13228 AB281
13228 AB291
13228 AB301
13228 AB311
13228 AB321
13228 AB331
13228 AB341
13228 AB351
13228 AB361
13228 AB371
13228 AB381
ME(H4DOTC)-42
Thickness mm (in)
4.68 (0.1843)
4.69 (0.1846)
4.70 (0.1850)
4.71 (0.1854)
4.72 (0.1858)
4.73 (0.1862)
4.74 (0.1866)
4.75 (0.1870)
4.76 (0.1874)
4.77 (0.1878)
4.78 (0.1882)
4.79 (0.1886)
4.80 (0.1890)
4.81 (0.1894)
4.82 (0.1898)
4.83 (0.1902)
4.84 (0.1906)
4.85 (0.1909)
4.86 (0.1913)
4.87 (0.1917)
4.88 (0.1921)
4.89 (0.1925)
4.90 (0.1929)
4.91 (0.1933)
4.92 (0.1937)
4.93 (0.1941)
4.94 (0.1945)
4.95 (0.1949)
4.96 (0.1953)
Valve Clearance
MECHANICAL
Part No.
13228 AB391
13228 AB401
13228 AB411
13228 AB421
13228 AB431
13228 AB441
13228 AB451
13228 AB461
13228 AB471
13228 AB481
13228 AB491
13228 AB501
13228 AB511
13228 AB521
13228 AB531
13228 AB541
13228 AB551
13228 AB561
13228 AB571
13228 AB581
13228 AB591
13228 AB601
13228 AB611
13228 AB621
13228 AB631
13228 AB641
13228 AB651
13228 AB661
13228 AB671
13228 AB681
13228 AB691
13228 AB701
13228 AB711
13228 AB721
13228 AB731
13228 AB741
13228 AB751
13228 AB761
13228 AB771
13228 AB781
13228 AB791
13228 AB801
13228 AB811
13228 AB821
13228 AB831
13228 AB841
13228 AB851
13228 AB861
13228 AB871
13228 AB881
13228 AB891
Thickness mm (in)
4.97 (0.1957)
4.98 (0.1961)
4.99 (0.1965)
5.00 (0.1969)
5.01 (0.1972)
5.02 (0.1976)
5.03 (0.1980)
5.04 (0.1984)
5.05 (0.1988)
5.06 (0.1992)
5.07 (0.1996)
5.08 (0.2000)
5.09 (0.2004)
5.10 (0.2008)
5.11 (0.2012)
5.12 (0.2016)
5.13 (0.2020)
5.14 (0.2024)
5.15 (0.2028)
5.16 (0.2031)
5.17 (0.2035)
5.18 (0.2039)
5.19 (0.2043)
5.20 (0.2047)
5.21 (0.2051)
5.22 (0.2055)
5.23 (0.2059)
5.24 (0.2063)
5.25 (0.2067)
5.26 (0.2071)
5.27 (0.2075)
4.38 (0.1724)
4.40 (0.1732)
4.42 (0.1740)
4.44 (0.1748)
4.46 (0.1756)
4.48 (0.1764)
4.50 (0.1771)
4.52 (0.1780)
4.54 (0.1787)
4.56 (0.1795)
4.58 (0.1803)
4.60 (0.1811)
4.62 (0.1819)
4.64 (0.1827)
4.66 (0.1835)
5.29 (0.2083)
5.31 (0.2091)
5.33 (0.2098)
5.35 (0.2106)
5.37 (0.2114)
Part No.
13228 AB901
13228 AB911
13228 AB921
13228 AB931
13228 AB941
13228 AB951
13228 AB961
13228 AB971
13228 AB981
13228 AB991
13228 AC001
13228 AC011
13228 AC021
13228 AC031
Thickness mm (in)
5.39 (0.2122)
5.41 (0.2123)
5.43 (0.2138)
5.45 (0.2146)
5.47 (0.2154)
5.49 (0.2161)
5.51 (0.2169)
5.53 (0.2177)
5.55 (0.2185)
5.57 (0.2193)
5.59 (0.2201)
5.61 (0.2209)
5.63 (0.2217)
5.65 (0.2224)
6) Inspect all valves for clearance again at this
stage. If the valve clearance is not correct, repeat
the procedure over again from the first step.
7) After inspection, install the related parts in the
reverse order of removal.
ME(H4DOTC)-43
Engine Assembly
MECHANICAL
9. Engine Assembly
A: REMOVAL
1) Set the vehicle on a lift.
2) Open the front hood fully, and then support with
the hood stay.
3) Collect the refrigerant from A/C system.
4) Release the fuel pressure.
(1) Disconnect the fuel pump relay connector.
10) Remove the intercooler. <Ref. to IN(H4DOTC)10, REMOVAL, Intercooler.>
11) Disconnect the following connectors and cable.
(1) Engine harness connector
ME-00027
(2) Engine ground terminal
FU-00871
(2) Start the engine, and run until stalls.
(3) After the engine stalls, crank it for 5 seconds
more.
(4) Turn the ignition switch to OFF.
5) Remove the filler cap.
6) Disconnect the ground cable from battery.
ME-00028
(3) Engine harness connector
FU-00009
7) Remove the radiator from vehicle. <Ref. to
CO(H4DOTC)-23, REMOVAL, Radiator.>
8) Remove the coolant filler tank. <Ref. to
CO(H4DOTC)-33, REMOVAL, Coolant Filler
Tank.>
9) Disconnect the A/C pressure hoses from A/C
compressor.
ME-00029
(4) Generator connector, terminal and A/C
compressor connectors
(B)
(A)
ME-00030
ME-00707
(A) A/C compressor connector
(B) Generator connector and terminal
ME(H4DOTC)-44
Engine Assembly
MECHANICAL
(2) Disconnect the power steering switch connector.
(5) Accelerator cable (MT model)
ME-00031
ME-00035
(6) Clutch release spring (MT model)
(3) Remove the pipe with bracket from intake
manifold.
ME-00032
12) Disconnect the following hoses.
(1) Brake booster vacuum hose
ME-00036
(4) Remove the power steering pump from engine.
ME-00033
(2) Heater inlet outlet hose
ME-00037
(5) Remove the power steering tank from
bracket by pulling it upward.
ME-00034
13) Remove the power steering pump from bracket.
(1) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt. <Ref. to
ME(H4DOTC)-54, FRONT SIDE BELT, REMOVAL, V-belt.>
ME(H4DOTC)-45
ME-00038
Engine Assembly
MECHANICAL
(6) Place the power steering pump on right side
wheel apron.
(2) Remove the plug using a 10 mm hexagon
wrench.
ME-00039
14) Lift-up the vehicle.
15) Remove the ATF cooler pipe from frame. (AT
model)
16) Remove the center exhaust pipe. <Ref. to
EX(H4DOTC)-9, REMOVAL, Center Exhaust
Pipe.>
17) Remove the nuts which hold the lower side of
transmission to engine.
ME-00042
(3) Screw the 6 mm dia. bolt into release fork
shaft, and remove it.
(A)
(B)
ME-00040
18) Remove the nuts which install the front cushion
rubber onto front crossmember.
ME-00043
(A) Shaft
(B) Bolt
(4) Raise the release fork, and then unfasten
the release bearing tabs to free release fork.
ME-00041
19) Lower the vehicle.
20) Separate the clutch release fork from release
bearing. (MT model)
(1) Remove the clutch operating cylinder from
transmission.
NOTE:
Step (4) is required to prevent interference with engine when removing the engine from transmission.
21) Separate the torque converter clutch from drive
plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Remove the bolts which hold the torque
converter clutch to drive plate.
ME(H4DOTC)-46
Engine Assembly
MECHANICAL
(4) Remove the other bolts while rotating the
engine using socket wrench.
25) Support the engine with a lifting device and
wire ropes.
ME-00047
ME-00044
26) Support the transmission with a garage jack.
22) Remove the pitching stopper.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under
its own weight.
MT-00069
23) Disconnect the fuel delivery hose, return hose
and evaporation hose.
NOTE:
• Catch fuel from the hose into container.
• Disconnect the hose with its end wrapped with
cloth to prevent fuel from splashing.
ME-00048
27) Separation of the engine and transmission.
(1) Remove the starter. <Ref. to SC(H4SO)-7,
REMOVAL, Starter.>
(2) Install the ST to torque converter clutch
case. (AT model)
ST 498277200
STOPPER SET
ME-00045
24) Remove the fuel filter and bracket.
ST
ME-00049
ME-00046
ME(H4DOTC)-47
Engine Assembly
MECHANICAL
(3) Remove the bolts which hold the right upper
side of transmission to engine.
(3) Install the release fork into release bearing
tab.
(A)
(B)
ME-00050
28) Remove the engine from vehicle.
(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
(3) Move the engine horizontally until the mainshaft is withdrawn from clutch cover.
(4) Slowly move the engine away from engine
compartment.
ME-00052
(A) Release fork
(B) Release bearing
(4) Apply grease to the specified points.
• Spline: FX2200
• Shaft: SUNLIGHT 2
NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
29) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission. (MT model)
(1) Remove the release bearing from clutch
cover with flat type screw driver.
(A)
(B)
ME-00051
ME-00053
(2) Install the release bearing on transmission.
(A) Spline (FX2200)
(B) Shaft (SUNLIGHT 2)
(5) Insert the release fork shaft into release
fork.
ME(H4DOTC)-48
Engine Assembly
MECHANICAL
CAUTION:
Make sure the cutout portion of release fork
shaft contacts spring pin.
(B)
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
(A)
(C)
ME-00050
ME-00054
(A) Release fork
(B) Release shaft
(C) Spring pin
5) Remove the lifting device and wire ropes.
6) Remove the garage jack.
(6) Tighten the plug.
Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)
ME-00047
7) Install the pitching stopper.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)
ME-00055
2) Install the front cushion rubbers to engine.
Tightening torque:
35 N·m (3.6 kgf-m, 25.8 ft-lb)
3) Install the engine onto transmission.
(1) Position the engine in engine compartment,
and then align it with the transmission.
NOTE:
Be careful not to damage the adjacent parts or
body panels with crank pulley, oil pressure gauge,
etc.
(2) Apply a small amount of grease to the
splines of mainshaft. (MT model)
4) Tighten the bolts which hold the right upper side
of transmission to engine.
T1
T2
MT-00085
8) Remove the ST from torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST 498277200
STOPPER SET
9) Install the starter. <Ref. to SC(H4SO)-7, INSTALLATION, Starter.>
10) Install the torque converter clutch onto drive
plate. (AT model)
(1) Tighten the bolts which hold the torque converter clutch to drive plate.
ME(H4DOTC)-49
Engine Assembly
MECHANICAL
(2) Tighten other bolts while rotating the engine
by using ST.
CAUTION:
Be careful not to drop bolts into the torque converter clutch housing.
ST 499977300
CRANKSHAFT PULLEY
WRENCH
(2) Install the power steering pump.
Tightening torque:
20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
ME-00037
(3) Install the power steering pipe bracket on intake manifold RH.
ME-00044
(3) Clog the service hole with plug.
11) Install the fuel filter and bracket.
ME-00036
(4) Connect the power steering switch connector.
ME-00046
12) Install the power steering pump on bracket.
(1) Install the power steering tank on bracket.
ME-00035
ME-00038
(5) Install the front side V-belt, and adjust it.
<Ref. to ME(H4DOTC)-54, FRONT SIDE BELT,
INSTALLATION, V-belt.>
13) Lift-up the vehicle.
14) Tighten the nuts which hold the lower side of
transmission to engine.
ME(H4DOTC)-50
Engine Assembly
MECHANICAL
(2) Install the air cleaner element and air cleaner upper cover.
(3) Install the engine harness connector bracket.
(4) Install the filler hose to air cleaner case.
24) Install the A/C pressure hoses.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)
NOTE:
Use new O-rings.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)
ME-00040
15) Tighten the nuts which install the front cushion
rubber onto crossmember.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
(B)
(A)
(A)
(B)
ME-00056
16) Install the ATF cooler pipe to frame. (AT model)
17) Install the center exhaust pipe.
<Ref. to EX(H4DOTC)-10, INSTALLATION, Center
Exhaust Pipe.>
18) Lower the vehicle.
19) Connect the following hoses:
(1) Fuel delivery hose, return hose and evaporation hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
20) Connect the following connectors and terminals:
(1) Engine ground terminal
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
21) Connect the following cables:
(1) Accelerator cable
(2) Clutch release spring
22) After connecting each cable, adjust them.
23) Install the air intake system.
(1) Install
the
intercooler.
<Ref.
to
IN(H4DOTC)-10, INSTALLATION, Intercooler.>
ME-00707
25) Install the radiator. <Ref. to CO(H4DOTC)-24,
INSTALLATION, Radiator.>
26) Install the coolant filler tank. <Ref. to
CO(H4DOTC)-33, INSTALLATION, Coolant Filler
Tank.>
27) Install the window washer tank.
28) Install the battery in the vehicle, and then connect the cables.
29) Fill coolant.
<Ref. to CO(H4DOTC)-18, FILLING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
30) Charge the A/C system with refrigerant.
<Ref. to AC-22, OPERATION, Refrigerant Charging Procedure.>
31) Remove the front hood stay, and close the front
hood.
32) Take off the vehicle from lift arms.
ME(H4DOTC)-51
Engine Mounting
MECHANICAL
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly. <Ref. to
ME(H4DOTC)-44, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine assembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
Engine mounting;
35 N·m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.
ME(H4DOTC)-52
Preparation for Overhaul
MECHANICAL
11.Preparation for Overhaul
A: PROCEDURE
1) After removing the engine from body, secure it in
the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND
ST2
ST1
ST3
ME-00057
2) In this section the procedures described under
each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described previously in order to do that particular procedure.
ME(H4DOTC)-53
V-belt
MECHANICAL
12.V-belt
4) Remove the A/C belt tensioner.
A: REMOVAL
1. FRONT SIDE BELT
1) Remove the V-belt cover.
ME-00061
B: INSTALLATION
NOTE:
Wipe off any oil or water on the belt and pulley.
ME-00708
2) Loosen the lock bolt (A).
3) Loosen the slider bolt (B).
4) Remove the front side belt (C).
1. FRONT SIDE BELT
1) Install a V-belt (C), and tighten the slider bolt so
as to obtain the specified belt tension. <Ref. to
ME(H4DOTC)-55, INSPECTION, V-belt.>
2) Tighten the lock bolt (A).
3) Tighten the slider bolt (B).
(B)
(C)
(A)
ME-00059
Tightening torque:
Lock bolt (A):
25 N·m (2.5 kgf-m, 18.1 ft-lb)
Slider bolt (B):
8 N·m (0.8 kgf-m, 5.9 ft-lb)
(B)
2. REAR SIDE BELT
(C)
1) Loosen the lock nut (A).
2) Loosen the slider bolt (B).
(A)
ME-00059
(B)
2. REAR SIDE BELT
(A)
ME-00060
1) Remove the A/C belt tensioner.
2) Install a V-belt, and tighten the slider bolt (B) so
as to obtain the specified belt tension.
<Ref. to ME(H4DOTC)-55, INSPECTION, V-belt.>
3) Remove the A/C belt.
ME(H4DOTC)-54
V-belt
MECHANICAL
3) Tighten the lock nut (A).
Belt tension (without belt tension gauge)
Tightening torque:
Lock nut (A):
22.6 N·m (2.3 kgf-m, 16.6 ft-lb)
(A)
When installing new parts:
7 — 9 mm (0.276 — 0.354 in)
At inspection:
9 — 11 mm (0.354 — 0.433 in)
(B)
When installing new parts:
7.5 — 8.5 mm (0.295 — 0.335 in)
At inspection:
9.0 — 10.0 mm (0.354 — 0.394 in)
(B)
(A)
98 N (10 kgf, 22 lb)
ME-00060
P/S
GEN
(A) (B)
A/C
C: INSPECTION
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the V-belt tension and adjust it if necessary by changing the generator installing position
and idler pulley installing position.
I/P
C/P
ME-00062
Belt tension (with belt tension gauge)
(A)
When installing new parts:
618 — 755 N (63 — 77 kgf, 139 — 170 lb)
At inspection:
490 — 640 N (50 — 65 kgf, 110 — 144 lb)
C/P
GEN
P/S
A/C
I/P
(B)
When installing new parts:
740 — 880 N (75 — 90 kgf, 166 — 198 lb)
At inspection:
350 — 450 N (36 — 46 kgf, 78 — 101 lb)
(A)
P/S
A/C
GEN
(B)
I/P
C/P
PM-00154
(A)
(B)
C/P
GEN
P/S
A/C
I/P
Front side belt
Rear side belt
Crank pulley
Generator
Power steering oil pump pulley
A/C compressor pulley
Idler pulley
ME(H4DOTC)-55
Crank pulley
Generator
Power steering oil pump pulley
A/C compressor pulley
Idler pulley